Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



During these procedures, identify all components removed from the engine so that they may be reinstalled in their original positions. If discarding the old components so that new components can be installed, identifying the old items is not necessary.

1.3L Engine

For the 1.3L engine, the carburetor may be removed prior to separating the intake manifold from the engine, or may be removed along with the intake manifold.

See Figures 1 through 10

  1. Disconnect the negative battery cable.
  2.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the cooling system.
  2.  
  3. Remove the air cleaner from the carburetor, and, if desired, the carburetor from the intake manifold.
  4.  
  5. Label and detach all electrical wiring, vacuum hoses and cooling system hoses from the intake manifold.
  6.  


WARNING
Never use a prybar between the intake manifold and cylinder head mating surface to attempt to separate the two components; damage to the intake manifold or cylinder head may occur, necessitating component replacement.

  1. Remove the intake manifold mounting fasteners, then remove the intake manifold from the cylinder head. It may be necessary to tap the manifold with a soft-faced mallet to free it from the cylinder head.
  2.  
  3. Insert clean shop rags in the intake holes in the cylinder head to prevent accidentally dropping anything (such as dirt, nuts, bolts, etc.), which would require cylinder head removal, into the cylinders.
  4.  
  5. If not already removed, the carburetor can now be separated from the intake manifold by loosening the mounting fasteners.
  6.  
  7. If a new manifold is to be installed, any components mounted on the intake manifold (such as the PCV valve, EGR valve, gas filter, thermostat, sensors, switches, etc.) may be removed from the intake manifold at this time.
  8.  
  9. Thoroughly clean all gasket mating surfaces of all dirt and old gasket material.
  10.  

To install:
  1. If a new manifold is being installed, transfer any manifold-mounted components to the new manifold.
  2.  
  3. Remove the rags from the cylinder head intake holes.
  4.  
  5. Position a new intake manifold gasket on the cylinder head, then install the intake manifold. Tighten the intake manifold-to-cylinder head bolts to 159-248 inch lbs. (18-28 Nm). Be sure to tighten the center bolts first, then work your way out to both ends of the manifold.
  6.  
  7. Reattach all electrical wiring, vacuum hoses and cooling system hoses to the intake manifold.
  8.  
  9. Install the carburetor onto the intake manifold, and the air cleaner onto the carburetor.
  10.  
  11. Fill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and inspect for engine coolant and fuel leaks.
  16.  



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Fig. Fig. 1: To remove the intake manifold, detach and label all wiring from the intake manifold sensors ...



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Fig. Fig. 2: ... or, when necessary, disengage any wiring connectors for wires leading to the intake manifold



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Fig. Fig. 3: Detach all ground wires from the manifold, including the one attached to the thermostat housing bolt



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Fig. Fig. 4: Label and detach all vacuum lines from the intake manifold and related components ...



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Fig. Fig. 5: ... and disconnect all cooling system hoses from the manifold



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Fig. Fig. 6: Before loosening the mounting fasteners, ensure that all wires and hoses are properly disconnected ...



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Fig. Fig. 7: ... then remove the mounting fasteners



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Fig. Fig. 8: Lift the intake manifold up and off of the cylinder head studs ...



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Fig. Fig. 9: ... and insert clean rags or paper towels in the cylinder head intake holes



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Fig. Fig. 10: Be sure to remove and discard the old intake manifold-to-cylinder head gasket

1.6L TFI Engines

See Figures 11, 12 and 13

  1. Remove the throttle body from the intake manifold.
  2.  
  3. Disconnect the PCV hose from the rocker arm cover.
  4.  
  5. Detach the pressure sensor hose from the gas filter.
  6.  
  7. Disconnect the brake booster and automatic transmission (if equipped) vacuum hoses from the intake manifold.
  8.  



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Fig. Fig. 11: Exploded view of the throttle body and intake manifold mounting

  1. Detach the Vacuum Switching Valve (VSV) hose for the throttle opener and EVAP canister from the intake manifold.
  2.  
  3. Detach the upper radiator hose from the thermostat housing, and the heater inlet and water bypass hoses from the intake manifold.
  4.  



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Fig. Fig. 12: Be sure to detach all hoses ...



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Fig. Fig. 13: ... as well as vacuum lines and wiring from the intake manifold, prior to removing the attaching fasteners

  1. Disconnect the EGR valve hoses from the EGR valve.
  2.  
  3. Detach and label all wiring and wiring connectors from components mounted on the intake manifold.
  4.  


WARNING
Never use a prybar between the intake manifold and cylinder head mating surface to attempt to separate the two components; damage to the intake manifold or cylinder head may occur, necessitating component replacement.

  1. Remove the intake manifold mounting fasteners, then remove the intake manifold from the cylinder head. It may be necessary to tap the manifold with a soft-faced mallet to free it from the cylinder head.
  2.  
  3. Insert clean shop rags in the intake holes in the cylinder head to prevent accidentally dropping anything (such as dirt, nuts, bolts, etc.), which would require cylinder head removal, into the cylinders.
  4.  
  5. At this time, the PCV valve, EGR valve, gas filter, thermostat, sensors, switch and gauge may be removed from the intake manifold.
  6.  
  7. Clean the intake manifold-to-cylinder head gasket mating surfaces thoroughly.
  8.  

To install:
  1. If a new manifold is being installed, transfer the PCV valve, EGR valve, gas filter, thermostat, sensors, switch and gauge to the new manifold.
  2.  
  3. Remove the rags from the cylinder head intake holes.
  4.  
  5. Position a new intake manifold gasket on the cylinder head, then install the intake manifold. Tighten the intake manifold-to-cylinder head bolts to 159-248 inch lbs. (18-28 Nm). Be sure to tighten the center bolts first, then work your way out to both ends of the manifold.
  6.  
  7. Reattach all wiring to the intake manifold and related components.
  8.  
  9. Reconnect the upper radiator, the bypass, the heater inlet, the pressure sensor, the VSV, the brake booster, the EGR valve, the automatic transmission, and the PCV hoses.
  10.  
  11. Install the throttle body.
  12.  

1.6L MFI Engines

See Figures 14, 15 and 16

  1. Relieve the fuel system pressure as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Drain the engine cooling system.
  2.  
  3. Remove the air intake pipe.
  4.  



Click image to see an enlarged view

Fig. Fig. 14: Exploded view of the intake manifold, throttle body and intake surge tank mounting

  1. Detach the accelerator cable and automatic transmission kickdown cable (if equipped) from the throttle body.
  2.  
  3. Detach the vacuum hose from the PCV valve.
  4.  
  5. Disengage all wiring from the intake manifold and throttle body which will interfere with removal.
  6.  
  7. Disconnect all vacuum and cooling system hoses from the throttle body and intake manifold which will restrict removal.
  8.  


WARNING
Be sure to plug the fuel lines to prevent dirt or other contaminants, which may cause future fuel system damage, from entering the fuel system.

  1. Disconnect and plug the fuel feed line from the junction near the firewall. Be sure to use a second wrench to hold the junction steady while loosening the fuel line flare nut. Also, detach the fuel return line.
  2.  
  3. Remove the alternator adjusting arm brace.
  4.  
  5. Remove the intake manifold brace, the No. 1 brace and the No. 2 brace with the EGR pressure transducer.
  6.  



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Fig. Fig. 15: Prior to removing the intake manifold, be sure to detach all cooling system hoses, vacuum lines and wires (shown by arrows) from the intake manifold, throttle body and surge tank

  1. Detach the cooling system bypass hose from the intake manifold.
  2.  


WARNING
Never use a prybar between the intake manifold and cylinder head mating surface to attempt to separate the two components; damage to the intake manifold or cylinder head may occur, necessitating component replacement.

  1. Remove the intake manifold-to-cylinder head mounting fasteners, then separate the intake manifold and throttle body assembly from the engine. It may be necessary to tap the manifold with a soft-faced mallet to free it from the cylinder head. At this point the throttle body and intake surge tank can be separated from the intake manifold by removing the attaching fasteners. Be sure to discard any old gaskets used between these components.
  2.  
  3. Insert clean shop rags in the intake holes in the cylinder head to prevent accidentally dropping anything (such as dirt, nuts, bolts, etc.), which would require cylinder head removal, into the cylinders.
  4.  
  5. Remove and discard the old intake manifold-to-cylinder head gasket.
  6.  
  7. Clean all gasket mating surfaces thoroughly.
  8.  



Click image to see an enlarged view

Fig. Fig. 16: The throttle body and surge tank are removed along with the intake manifold as an assembly, then they may be separated

To install:
  1. If necessary, assemble the intake surge tank and throttle body onto the intake manifold, making sure to use new gaskets and to tighten the attaching fasteners to 203 inch lbs. (23 Nm).
  2.  
  3. Remove the rags from the cylinder head intake holes.
  4.  
  5. Position a new intake manifold gasket on the cylinder head studs, then install the intake manifold and throttle body assembly onto the cylinder head. Be sure to install the wiring clamps on their original studs.
  6.  
  7. Starting in the middle of the intake manifold and working outward toward the ends, tighten the manifold mounting fasteners to 203 inch lbs. (23 Nm).
  8.  
  9. Reattach the cooling system bypass hose to the intake manifold.
  10.  
  11. Install the intake manifold brace, the No. 1 brace and the No. 2 brace with the EGR pressure transducer. Tighten the brace fasteners to 7 ft. lbs. (50 Nm).
  12.  
  13. Install the alternator adjusting arm brace. Tighten the brace bolts to 7 ft. lbs. (50 Nm).
  14.  
  15. Attach the fuel feed line to the junction near the firewall. Be sure to use a second wrench to hold the junction steady while tightening the fuel line flare nut to 3.5 ft. lbs. (45 Nm). Also, reattach the fuel return line.
  16.  
  17. Connect all vacuum and cooling system hoses to the throttle body and intake manifold.
  18.  
  19. Engage all wiring to the intake manifold and throttle body.
  20.  
  21. Connect the PCV vacuum hose to the valve.
  22.  
  23. Reattach the accelerator cable and automatic transmission kickdown cable (if equipped) to the throttle body. Be sure to adjust the accelerator and kickdown (if equipped) cables play. Accelerator cable play adjustment is covered in Fuel System , and kickdown cable adjustment is described in this guide.
  24.  
  25. Install the air intake pipe.
  26.  
  27. Fill the engine cooling system.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Turn the ignition key ON , but do not start the engine; this allows the fuel system to pressurize. Check for fuel system leaks.
  32.  
  33. Afdter checking for fuel system leaks, start the engine and inspect for engine coolant leaks.
  34.  

1.8L Engine

See Figures 17 and 18

  1. Remove the throttle body from the intake manifold.
  2.  
  3. Remove the front and rear intake manifold braces.
  4.  
  5. Detach the water pipe from the intake manifold.
  6.  


WARNING
Never use a prybar between the intake manifold and cylinder head mating surface to attempt to separate the two components; damage to the intake manifold or cylinder head may occur, necessitating component replacement.

  1. Remove the intake manifold mounting fasteners, then separate the manifold from the cylinder head. It may be necessary to tap the manifold with a soft-faced mallet to free it from the cylinder head.
  2.  



Click image to see an enlarged view

Fig. Fig. 17: Exploded view of the intake manifold and throttle body mounting

  1. Insert clean shop rags in the intake holes in the cylinder head to prevent accidentally dropping anything (such as dirt, nuts, bolts, etc.), which would require cylinder head removal, into the cylinders.
  2.  
  3. Remove and discard the old intake manifold gasket. Thoroughly clean all gasket mating surfaces of all dirt and old gasket material.
  4.  
  5. If a new manifold is being installed, remove the EVAP solenoid purge valve, Exhaust Gas Recirculation (EGR) valve, Idle Air Control (IAC) valve, EGR pipe and vacuum pipe from the old intake manifold.
  6.  



Click image to see an enlarged view

Fig. Fig. 18: If a new intake manifold is being installed, transfer all intake manifold components over to the new manifold

To install:
  1. Clean all gasket mating surfaces thoroughly.
  2.  
  3. If necessary, transfer the EVAP solenoid purge valve, Exhaust Gas Recirculation (EGR) valve, Idle Air Control (IAC) valve, EGR pipe and vacuum pipe onto the new intake manifold.
  4.  
  5. Remove the rags from the cylinder head intake holes.
  6.  
  7. Along with a new gasket, install the intake manifold onto the cylinder head. Starting in the middle of the intake manifold and working outward toward the ends, tighten the manifold mounting fasteners to 203 inch lbs. (23 Nm).
  8.  
  9. Connect the water pipe to the intake manifold.
  10.  

Install the front and rear intake manifold braces. Tighten the front brace bolts to 7.5 ft. lbs. (50 Nm), and the rear manifold brace bolts to 221 inch lbs. (25 Nm).

  1. Install the throttle body.
  2.  

 
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